headlight mod "how to"

[Burns]

My headlight often requires several on/off ignition switch operations to illuminate and I fear that it will leave me in the dark some dark and rainy night.  Rather than just fix the immediate problem I'd like to do the "head light mod" (relays) and - unless otherwise advised by you good folks - eliminate the reserve lighting unit while I'm in there.

My searches for threads describing how to perform those tasks produced lots of results with references to the mods  but nothing resembling instructions.

If there is a thread (or threads) with that info would somebody kindly point me to it?

I'd sure appreciate it.

Thank you

Happy Trails

[4everFJ]

http://www.fjowners.com/index.php?topic=660.0

http://www.fjowners.com/index.php?topic=2033.0

[Pat Conlon]

Where would you go to get info on modifications? Hmmmm...
Did you check our Modification Files?
http://www.fjowners.com/index.php?topic=2033.0

You can buy the components and build a harness yourself with the above info, or you can buy one already made for you... http://www.easternbeaver.com/

That said, I think your troubles are elsewhere. Sounds like you have a switching problem that a relay harness will not correct.

[Burns]

Thanks Pat.  Do you suspect the main switch to be the problem? Or perhaps a loose connection?  Any suggestions as to where I should look for this Gremlin?

[Burns]

thanks to all. I was hoping to locate a step-by-step instructional (with photos if possible), if anyone knows of such a thing, since it will all look like spaghetti to me. Looks like I have some homework to do.  I'll jump the main switch to locate or eliminate that as a problem before I go further. 
Any tips will be deeply appreciated.

[Pat Conlon]

Thanks Pat.  Do you suspect the main switch to be the problem? Or perhaps a loose connection?  Any suggestions as to where I should look for this Gremlin?

After 30 years and 150k miles, my ignition key switch just wore out (they do that) and just like yours, mine started giving me warnings.

$40 later I am good to go...

[Burns]

I have another one on my parts bike, so that's the first thing I'll check.  The bike starts and I'm wondering if the headlight interrupt for cranking is the problem. There's a switch in the circuit that opens or closes in response to alternator current, i.e kicks the headlight out of the circuit with a dead engine and in with a running motor, isn't there?

[Pat Conlon]

Correct, there is a starter relay that drops out the headlight when the starter button is pushed and the starter motor is energized.
However, that is not what you described.

My headlight often requires several on/off ignition switch operations to illuminate

[Burns]

My bad, Pat. My description was incomplete.  The problem is intermittent; I just went out to check it and everything is working correctly. But my recollection is that the headlight usually comes on when the ignition switch is turned to on - though I think sometimes just the pilot light comes on, the headlight goes out when I crank the engine, and sometimes does not come back on when the motor fires up.

It sounds like a relay issue.  Where is that headlight interrupt rascal located?

[Pat Conlon]

Common problem is that your starter button does not fully pop back out when you release it. This will interrupt your headlight. Clean it first.

The starter relay on my '84 is above the engine in front of the battery box.

[Burns]

That makes absolute sense. Sometimes the starter motor "hangs" - no doubt because of that same button. Weak spring maybe?   I think you've put me straight on this one.  Thanks much.

[Pat Conlon]

Yep, along with a dark headlight, a hanging starter is a sure symptom of a sticky start button.

[Burns]

well I see the light now and it is (wait for it) right on the button.

[FJ_Hooligan]

Hopefully it's an easy fix, but if you do any riding at night keep considering the relay mod.

[Burns]

I'm planning on doing it this Winter.  I have what will probably be my last ride of the Season coming up in a couple weeks and have plenty to do from now to then - Pat's insight was a life-saver - but after that I'll take her shirt off and brighten up her candles.